Thermal Coating Torch Wire End Alignment via Optical Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal coating devices for surfaces, such as those used in the automotive industry for cylinder bore coatings, face challenges in precisely and efficiently aligning the wire end relative to the plasma gas jet, leading to incomplete melting and reduced coating quality due to imprecise and time-consuming manual adjustment processes.
Innovation Solution
Incorporation of a measuring device, either optical or tactile, attached to the spray torch to accurately determine the wire end's position and required adjustment path, coupled with a mechanically or electrically driven adjustment system for automated alignment, ensuring precise and rapid adjustment of the wire end relative to the plasma gas jet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual adjustment of wire end position is used, then device complexity is reduced, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated measuring device that uses optical or tactile sensors to detect wire end position and shape, substituting human estimation and manual screw adjustment with automated measurement and control systems
Solution Approach 2:
The measuring device enables the system to automatically determine the wire end position and calculate required adjustment amounts without external intervention, making the system self-adjusting through automated feedback from the sensors
2Device complexity
If manual adjustment process is used, then device complexity is reduced, but productivity deteriorates due to time-consuming adjustments
Solution Approach 1:
The patent replaces time-consuming manual adjustment operations with automated optical or tactile measurement systems that instantly detect wire end position and calculate adjustment requirements, dramatically reducing alignment time
Solution Approach 2:
The measuring device provides real-time feedback on wire end position and shape, enabling automated control systems to make precise adjustments without manual intervention, thereby increasing productivity through rapid iterative correction
3Manufacturing precision
If measuring device is added to spray torch, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The measuring device is designed to serve multiple functions: detecting wire end position, determining wire end shape, calculating adjustment amounts, and providing feedback for automated control, thereby justifying the added complexity through multi-functionality
Solution Approach 2:
The measuring device acts as an intermediary between the wire feed system and the control system, translating physical wire end characteristics into measurable data that can be processed for automated adjustment decisions
4Productivity
If automated adjustment system is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent replaces manual mechanical adjustment with automated optical or tactile measurement systems coupled with control algorithms, substituting human operations with automated sensing and actuation systems
Solution Approach 2:
The system automatically measures wire end position, calculates required adjustments, and executes correction without external intervention, making the adjustment process self-service and thereby increasing productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise and time-saving alignment of the wire end, resulting in improved coating quality by ensuring complete melting of the wire end and reducing the likelihood of defects in the coating layer.
Implementation Method 1
an optical sensor (42) which detects the shape of the wire end (18)
Implementation Method 2
the measuring device (40) is designed as a tactile measuring system with at least one probe
Implementation Method 3
a plasma gas source (not shown in the figures), which generates a plasma gas stream directed towards the wire end (18)... an arc is generated between the first electrode and the wire, and the resulting high temperature melts the wire end
Implementation Method 4
an arc is generated between the first electrode and the wire, and the resulting high temperature melts the wire end
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Device for thermally coating a surface with a spray torch (2) comprising a wire feed device (4) with at least one guide element (10, 12) for guiding a wire (16), a plasma gas source, a nozzle assembly (6) with a nozzle opening (14) for generating a plasma gas jet directed towards a wire end (18), a first electrode (20) and a second electrode (22), wherein the wire (16) acts as the second electrode (22), and an adjustment device (26) by which the wire end (18) can be adjusted by a defined adjustment path. In such an embodiment, the adjustment path is estimated and aligned by repeatedly adjusting the wire relative to the plasma gas jet, which makes adjusting the wire end very time-consuming.According to the invention, it is therefore proposed that a measuring device (40) is provided which is attached to the spray torch (2) in a defined position, wherein the position or shape of the wire end (18) can be determined via the measuring device (40).